Audiomaster

I purchased my first ZJ today.

It is a 1994 with the 5.2 V8. The guy who sold it too me said the T Case had a bit of a grind when you engaged it into 4 lo. During the test drive we took it out on a dirt road I slowed down to a crawl put the transmission in neutral and then pulled the lever it went right into 4 lo no grind no nothing, pulled hard in 4 lo with no strange noises not a thing.

I shifted out of 4 lo and it felt really loose shifting out, almost popped out on its own. We drove around some more and the owner commented on how he had never in the 8 years he and owned it had it shift so easily into 4 lo. He kept going on about it so i decided to shift into 4 lo again, repeated the same steps above to no avail, lever goes all the way back but no 4 lo. No lo range light on the display and when you put it back into drive it acts like the T case is still in N. We tried several times to get it to engage. In order to get it back into 4 all time we had to shut the engine down to avoid grinding.

Because of this flaw I ended up getting this great condition ZJ for $1000. Since it was a 2.5/hr drive home I haven't had a chance to really get into it yet.

Is it possible for the linkage to come out of adjustment to the point where it won't engage? I have a hard time thinking the low range is gone as it engaged and pulled hard with no grinding or noise. This is the first time I've delt with this type of transfer case.

Only other problem is you have to shift it into neutral on occasion to start it as it won't start in park and I always have to move the lever past the OD to 2 then back to OD position to select overdrive, it's like the linkage on the AT is messed up also.

Everything else running and working great!


Thoughts, ideas, directions before I tear into my new girl?

Thanks!

freegdr

very possible,climb under and look

ol"blue

Welcome to CF.
It could be the t-case linkage, a broken mount, or internal shift fork damage.
As for your trans, the linkage between the floor shifter and the transmission lever (on the left side) might need adjusting. And it could be the Neutral Safety switch not letting it start in park. If you have the AW4 it's on the right side of trans and can be removed, cleaned, & adjusted. If it's the 42RE the NSS is on the left side and isn't adjustable, but is pretty cheap.
The AW4 was used in '93 & I think in some '94's. Your V8 probably has the 42RE.

BatmansZJ

I have a 94 zj also with v8 and I have the same problem with the shifter also when I start it can the linkage be adjusted I have no problem with the 4 lo

ol"blue

Are you referring to the transmission linkage?

BatmansZJ

Just have the same problem with starting sometimes it will start in p and sometimes not

ol"blue

The directions are on here somewhere, I'll see if I can find them.

ol"blue

Gearshift Adjustment Procedure
(1) Shift transmission into Park.
(2) Raise vehicle.
Fig. 264 Throttle Cable Attachment At Engine

Fig. 265 Throttle Cable Attachment At Transmission


ADJUSTMENTS (Continued)
(3) Release cable adjuster clamp (at transmission
end of cable) to unlock cable.
(4) Unsnap cable from cable mounting bracket on
transmission (Fig. 266).
(5) Slide cable eyelet off transmission shift lever.
(6) Verify transmission shift lever is in Park
detent by moving lever fully rearward. Last rearward
detent is Park position.
(7) Verify positive engagement of transmission
park lock by attempting to rotate propeller shaft.
Shaft will not rotate when park lock is engaged.
(8) Slide cable eyelt onto transmission shift lever.
(9) Snap shift cable adjuster into mounting
bracket on transmission.
(10) Lock shift cable by pressing cable adjuster
clamp down until it snaps into place.
(11) Lower vehicle and check engine starting.
Engine should start only in Park and Neutral.

BatmansZJ

Thank you much

ol"blue

Glad to be of help when/if I can.

Audiomaster

Excellent on the shifter adjustment. I'll check on the linkage on the T-Case and get some pics and let you guys know.

I've heard a lot of mixed stuff about the NP249. There are a lot of war cries about swapping and many that say as long as it is maintained and not worn out the viscous coupler is strong and works well. For me here in Southern Utah I like the idea of having the all wheel drive when it rains, snows, gets slick and not having to stop ever to pull the lever seems nice.

I plan on putting this Jeep on 35s swapping the rear axle and locking it up, can this T Case take the heavy amount of torque that the 242 can take? Or should I even be worried?

Bustedback

I'm not sure if the NP249 can handle lockers and big tires, I do know the front axle shafts on the AWD ZJs are the weakest link with stock tires, you throw some 35s on there and you may have some breakage issues in no time.

Audiomaster

GREAT NEWS! It was the linkage. The pin that holds the torque shaft on the linkage popped out of the bushing on the T-Case the PO must have bumped it on something. I was able to engage it in 4 Lo from below no problem. It's pretty rusted up so I need to let the bolts soak so I can get it all back in place.

Here is a pic:

ol"blue

That's good to hear.